UPRIGHT VACUUM WITH AN AUTOMATED DIVERTER VALVE
A vacuum cleaner with an automated diverter valve is described. The vacuum includes a handle, body, base, an automated diverter valve and air duct including two input ports. An automated diverter valve assembly at the junction of the dirty air intake within the base extends the air duct within the base and connects to the main air duct of the vacuum to the beater bar input and an attachment input. The automated diverter valve causes the air intake of the vacuum to be drawn from either the beater bar (floor) air input or the attachment input depending upon the position of the vacuum handle.
The present teachings are directed toward the improved cleaning capabilities of upright vacuum cleaners. In particular, the disclosure relates to an automated diverter valve in an upright vacuum cleaner that allows intake from a beater bar or a hand held attachment.
BACKGROUNDA need has been recognized in the vacuum cleaner industry for an upright vacuum cleaner that can be used with attachments. As such, there exists a need for a vacuum that can draw dirty air from a beater bar and draw dirty air from a hand held attachment. This vacuum needs to function such that the vacuum draws dirty air from a beater bar intake without having the dirty air traverse through a hand held attachment intake and vice versa. The upright vacuum cleaner should be able to effect this change quickly and easily. The upright vacuum cleaner should also be able to effect this change with minimal inconvenience.
The prior art upright vacuum cleaners often utilize the same input port for both the beater bar and a hand held attachment, or utilize separate intake ports for the beater bar and hand held attachments. However, these designs have many drawbacks. In vacuum cleaners where the upright vacuum cleaners utilize the same input port for both the beater bar and a hand held attachment, the use of the hand held attachment is difficult to engage, and often requires shutting off the vacuum in order to switch between the beater bar and the hand held attachment. The prior art upright vacuum cleaners that utilize separate intake ports for the beater bar and the hand held attachment require the user to manually divert the air from one intake to the other. These valves are often inconvenient to use and often require shutting down the vacuum unit. The prior art does not, however, exemplify upright vacuum cleaners with easy, convenient mechanisms which facilitate the operator's ability to switch between using a beater bar and a hand held attachment. Often, prior art air diverting systems in upright vacuum cleaners leak—causing air to be drawn in from both beater bar and hand held port—thereby reducing the overall cleaning effectiveness of both the beater bar and the hand held attachment. Furthermore, prior art manual air diverting systems are undesirably located on the base and require shutting off the motor in order to change between the beater bar and a hand held attachment. Lastly, as the prior art manual air diverting systems are undesirably located on the floor, it can be awkward for users, especially users with back problems, to reach the control to use the air diverting system.
SUMMARYAccording to one embodiment, a vacuum cleaner with an automated diverter valve is described. The vacuum cleaner comprises a diverter valve assembly comprising a first input port, a second input port, an output port, and an automated diverter to direct airflow from the first input port to the output port while blocking airflow from the second input port.
In some embodiments the diverter directs airflow from the second input port to the output port while blocking airflow from the first input port.
In some embodiments the vacuum cleaner further comprises a servo assembly for moving the automated diverter from the first input port to the second input port.
In some embodiments the vacuum cleaner further comprises a control board to operate the servo assembly in a desired rotational movement for a duration in order to selectively switch the automated diverter between the first input port and the second input port.
In some embodiments the vacuum cleaner further comprises a signal from a user actuated switch, wherein the signal is used by the control board to selectively switch the automated diverter between the first input port and the second input port. In some embodiments the user actuated switch comprises a magnetic sensor disposed fixedly in the vacuum and a magnet disposed in a rotatable portion of the vacuum, wherein placing a handle in a locked position rotates the rotatable portion, and disposes the magnet opposite the magnetic sensor.
In some embodiments the diverter valve assembly comprises a vacuum attitude sensor, wherein a detection signal from the vacuum attitude sensor selectively switches the automated diverter between the first input port and the second input port.
In some embodiments the vacuum cleaner further comprises an attachment sensor signal to denote the absence of an attachment connected to the first input port, and the absence of the attachment directs the control board to direct airflow from the second input port to the output port.
In some embodiments the servo assembly comprises a servo motor and a gear assembly, wherein the servo assembly is able to position the diverter as desired in two seconds or less.
In some embodiments the diverter valve assembly includes detents to stop a movement of the automated diverter.
In some embodiments the first input port is for receiving airflow from an attachment and the second input port is for receiving airflow from a beater bar.
In some embodiments the vacuum cleaner further comprises a dirt capturing device coupled to the output port of the diverter valve.
In some embodiments the vacuum cleaner further comprises a base attached to the handle, wherein a locked position of the handle raises the base.
In some embodiments, the automatic diverter assembly comprises a cylindrical conduit having a radius and the automatic diverter comprises a cylindrical shaped portion having a radius less than the radius of the cylindrical conduit, with the cylindrical shaped portion is inserted in the cylindrical conduit and is rotatable therein.
In some embodiments, the automatic diverter comprises a valve sheathing disposed on the cylindrical shaped portion and a low friction film disposed on the valve sheathing, with the low friction film in contact with the cylindrical conduit.
According to various embodiments, a method of diverting airflow along an air path in a vacuum cleaner is described. The method comprises providing a vacuum cleaner comprising a diverter valve assembly comprising a first input port, a second input port, an output port, an automated diverter; and moving the automated diverter between the first input port and the second input port so that the output port receives airflow from one of the input ports while blocking airflow from the other.
In some embodiments, the method comprises determining the position of the automated diverter based on a position of a vacuum handle. In some embodiments, the method comprises raising a portion of a vacuum base to prevent a beater bar from contacting a cleaning surface when a handle is in a locked position.
In some embodiments, the method comprises receiving airflow from an attachment with the first input port; receiving airflow from a beater bar with the second input port; and selecting to receive airflow from the first input port when a handle is in a locked position. The method can also comprise disabling the first input port when an attachment is not connected to the first input port. According to various embodiments, the method can include selecting to receive airflow from the second input port when the handle is not in the locked position. The method can be implemented in an upright vacuum.
The same reference number represents the same element on all drawings. It should be noted that the drawings are not necessarily to scale. The foregoing and other objects, aspects, and advantages are better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
The present teachings provide an upright vacuum cleaner including improved cleaning features. The essential structure of the vacuum comprises a handle, body, base, automated diverter valve and air duct including two input ports. An automated diverter valve assembly at the junction of the dirty air intake within the base extends the air duct within the base and connects to the main air duct of the vacuum to the beater bar input and an attachment input. The automated diverter valve causes the air intake of the vacuum to be drawn from either the beater bar (floor) air input or the attachment input. The main air duct is in air flow communication with a vacuum motor located in the body of the vacuum spaced from a distal end of the air duct with respect to the flow of air.
In some embodiments the vacuum cleaner comprises a servo assembly for moving the automated diverter from the beater bar input port to the attachment input port. In some embodiments the vacuum cleaner comprises a control board to operate the servo assembly in a desired rotational movement between the two input ports for a duration. In some embodiments the vacuum cleaner further comprises a signal from a user actuated switch, wherein the signal can be used by the control board to determine the valve position between the first input port and the second input port. In some embodiments the user actuated switch comprises a magnetic sensor disposed fixedly in the vacuum, and a magnet disposed in a rotatable portion of the vacuum, wherein placing the handle in a locked position rotates the rotatable portion, and disposes the magnet opposite the magnetic sensor. In some embodiments the diverter valve assembly comprises a vacuum attitude sensor, wherein a detection signal from the vacuum attitude sensor determines the valve position between the first input port and the second input port. In some embodiments the vacuum cleaner further comprises an attachment sensor signal to denote the absence of an attachment connected to the first input port, and the signal directs the control board to direct airflow from the second input port to the output port.
In some embodiments the servo assembly comprises a servo motor and a gear assembly, wherein the servo assembly is able to position the diverter as desired in two seconds or less. In some embodiments the diverter valve assembly includes detents to stop a movement of the automated diverter. In some embodiments, the rotatable scroll can be part of an upright vacuum cleaner in which the vacuum motor is located in the air path that contains dirt from a cleaning surface (sometimes referred to as a “dirty-air” type vacuum).
The result is an upright vacuum with significantly greater cleaning capability and ease of use. Since the diverter valve rotates between the beater bar input port and the attachment port automatically, an operator generally need not work as hard to utilize either the attachment or floor features of the vacuum. The diverter valve essentially seals the airflow path to direct air from only one input, thereby increasing the suction to any one input without suction loss from the other input port. Further, the vacuum cleaner need not shut the motor down when switching between beater bar and hand held use.
In a preferred embodiment, the bristle tufts can be arranged in a single helix or helical row. The single helical row can reverse its direction of rotation, e.g., at bristle tuft 173 in
Circuit board 260 of
In some embodiments automated diverter valve 192 includes detents to stop its movement. For example, diverter valve 212 can include diverter valve detents 198 and 202, where a wall of diverter valve 212 forms a ridge. A wall 211 of diverter valve 212 can be placed adjacent to a wall 217 of the diverter valve assembly against which servo assembly 192 is secured; this wall can a include bump-out 219 (see
In some embodiments, diverter valve 212 includes a low friction film 215 and a protective valve sheathing 213 deposed underneath. Protective valve sheathing 213 aids in sealing the diverter valve 212 over input port 206 or 204 as selected. Low friction film 215 allows diverter valve 212 to easily rotate between input port 206 and 204. Protective valve sheathing 213 can be manufactured from, without limitation to, plastic, foam, felt, plastic or other suitable materials, or combinations therein. Low friction film 215 can be smooth film.
As seen in
In some embodiments, scroll 218 comprises a magnet 224. A magnetic sensor 210 (see
Scroll ring 230 is disposed about motor housing cap 246. Key tabs 231a, 231b, and 231c are received by motor housing cap 246 to properly orient scroll ring 230 and scroll ring tab 232. Motor assembly 240 is fixedly disposed in base 102. As such, scroll ring 230 is fixedly disposed in base 102, i.e., scroll ring 230 does not rotate. However, scroll 218 rotates about scroll ring 232 so that handle 120 can rotate. Rotation of scroll 218 causes bag slide (see
Base 102 can be an airtight chamber. As seen in
Centrifugal fan 250 can include multiple fan blades and a hub. Centrifugal fan blades can have a slight backward curve. Alternatively, the fan can be axial or squirrel cage fans, or other material handling fans. In some embodiments, fan 250 can be made of one or more of a combination of materials, including metals, such as aluminum or plastic. In some embodiments fan 250 can be a centrifugal fan with a slight backward curve including 30 blades made by injection molding. In some embodiments, fan 250 can generate a blade pass frequency (BPF) that is greater than the BPF of prior art fans. The fan BPF noise level intensity varies with the number of blades and the rotation speed and can be expressed as BPF=n*t/60, where BPF=Blade Pass Frequency (Hertz (Hz)), n=rotation velocity (rpm), and t=number of blades. In noise profiles of a fan, high-amplitude spikes are observed at the BPF and at the harmonics of the BPF. Humans perceive sound frequencies ranging from 20 to 15,000 Hz. Moreover, sounds between 2,000 to 4,000 Hz are often perceived as very irritating and annoying to humans.
Prior art fans for motors used in vacuums generally use a stamped radial fan blade, a fan with blades extending out from the center along radii, usually comprising 2-12 blades. For example, in the prior art a vacuum motor having a 12-blade fan and operating at about 20,000 RPM would have a calculated BPF of about 4000 Hz. As can be seen in
By using a fan with a greater number of blades, the BPF can be manipulated to fall outside a desired sound frequency band. For example, the fan can comprise 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40 or more blades. A further advantage is that the unique design of motor assembly 240 and blade 250 includes a bigger blade surface area. Furthermore, this increase in blade area coupled with the greater number of blades in the fan can generate a greater airflow. The greater airflow can by generated by a motor assembly cap having the same or less volume than a motor assembly cap housing of prior art. By manipulating the number of blades and the RPMs of the fan, the BPF can be adjusted to spike at a frequency greater than about 5000, 5500, 6000, 6500, 7000, 7500, 8000, 8500, 9000, 9500, 10,000 or more Hz. A change in the blade pass frequency of the fan provides a reduction in perceived motor and fan noise. In some embodiments, the noise spikes generated by the fan is selected such that a BPF spike is outside a human ear's irritation noise range. Further in some embodiments, a BPF spike is generated outside of a human ear's audible noise range. In some embodiments motor assembly 240 can operate at about 10,000 to about 20,000 rotations per minute (RPM). In some embodiments assembly 240 can operate at about 10,000 or about 20,000 RPM. In some embodiments assembly 240 can operate at about 13,000 or about 18,000 RPM.
As seen in
Vacuum cleaner 100 can be capable of detecting blockage along an airpath of vacuum 100 by determining the amperage flow of the electrical current, and detecting blockage along an airpath by sampling the amperage flow of the electrical current and counting how many times the sampled amperage draw exceeds a threshold amperage within a window of time. When the samples sampled exceeds the percent threshold determined, power to motor assembly 240 is terminated. Optionally, an indicator light can be illuminated when power is shut-off. After receiving a reset signal the current flow to the motor can be restored.
Vacuum cleaner 100 and circuit board 260 can comprise multiple sensors and switches. In a broad sense, a “sensor” as used herein, is a device capable of receiving a signal or stimulus (electrical, temperature, time, etc.) and responds to it in a specific manner (opens or closes a circuit, etc.). A “switch,” as used herein, can be a mechanical or electrical device for making or breaking or changing the connections in a circuit. In some embodiments sensors can be switches. In other embodiments the sensors are connected to indicator lights or the like to inform a user of a malfunction or the need to perform a necessary function. Vacuum cleaner 100 or circuit board 260 can comprise flow blockage, light, temperature, “bag full” sensors, and handle attitude sensors. Signals from these sensors can aid the user in using and assessing various states of the vacuum. Sensors can comprise electric, magnetic, optical, gravity, etc., sensors, as known in the art. Vacuum cleaner 100 or circuit board 260 can further comprise a “deadman” or “kill” switch which is capable of terminating power to the vacuum should the user become incapacitated. A temperature sensor 266 can determine the temperature of motor assembly 240, base 102, or other parts. Circuit board 260 can turn on an indicator light and/or terminate power to vacuum 100. Further, vacuum cleaner 100 or circuit board 260 can include a reset switch which is capable of resetting power to vacuum cleaner 100 or circuit board 260.
As shown in
In some embodiments, vacuum cleaner 100 includes a temperature sensor 266 that is capable of determining the operating temperature of motor assembly 240 at step 290. When the operating temperature exceeds a predetermined high temperature threshold at step 292, power to motor assembly 240 is shut off at step 300. Optionally, an indicator light is illuminated at step 304 to notify the user of the temperature exceeded error condition. The current flow to the motor can be restored after receiving a reset signal at step 302. In some embodiments, the reset can be automatic if the operating temperature comes down to be within a temperature operating range. In some embodiments, the threshold temperature can be greater than 150, 175, 200 degree Celsius.
The various embodiments described above are provided by way of illustration only and should not be constructed to limit the invention. Those skilled in the art will readily recognize the various modifications and changes which may be made to the present invention without strictly following the exemplary embodiments illustrated and described herein, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.
Claims
1. A vacuum cleaner comprising a diverter valve assembly comprising;
- a first input port;
- a second input port;
- an output port; and
- an automated diverter to direct airflow from the first input port to the output port while blocking airflow from the second input port.
2. The vacuum cleaner of claim 1, wherein the automated diverter directs airflow from the second input port to the output port while blocking airflow from the first input port.
3. The vacuum cleaner of claim 1, further comprising a servo assembly for moving the automated diverter from the first input port to the second input port.
4. The vacuum cleaner of claim 3, further comprising a control board to operate the servo assembly in a desired rotational movement for a duration in order to selectively switch the automated diverter between the first input port and the second input port.
5. The vacuum cleaner of claim 4, further comprising a signal from a user actuated switch, wherein the signal is used by the control board to selectively switch the automated diverter between the first input port and the second input port.
6. The vacuum cleaner of claim 5, wherein the user actuated switch comprises a magnetic sensor disposed fixedly in the vacuum, and a magnet disposed in a rotatable portion of the vacuum, wherein placing a handle in a locked position rotates the rotatable portion, and disposes the magnet opposite the magnetic sensor.
7. The vacuum cleaner of claim 4, wherein the diverter valve assembly comprises a vacuum attitude sensor, wherein a detection signal from the vacuum attitude sensor selectively switches the automated diverter between the first input port and the second input port.
8. The vacuum cleaner of claim 4, further comprising an attachment sensor signal to denote the absence of an attachment connected to the first input port, and an absence of the attachment directs the control board to direct airflow from the second input port to the output port.
9. The vacuum cleaner of claim 1, further comprising valve sheathing disposed in contact with one or more of the first input port, the second input port, and the output port.
10. The vacuum cleaner of claim 1, wherein the diverter valve assembly includes detents to stop a movement of the automated diverter.
11. The vacuum cleaner of claim 1, wherein the first input port is for receiving airflow from an attachment and the second input port is for receiving airflow from a beater bar.
12. The vacuum cleaner of claim 1, further comprising a dirt capturing device coupled to the output port of the diverter valve.
13. The vacuum cleaner of claim 1, wherein the vacuum cleaner is an upright vacuum cleaner that further comprises a base attached to a handle, wherein a locked position of the handle raises the base.
14. The vacuum cleaner of claim 1, wherein the automatic diverter assembly comprises a cylindrical conduit having a radius and the automatic diverter comprises a cylindrical shaped portion having a radius less than the radius of the cylindrical conduit, with the cylindrical shaped portion is inserted in the cylindrical conduit and is rotatable therein.
15. The vacuum cleaner of claim 14, wherein the automatic diverter comprises a valve sheathing disposed on the cylindrical shaped portion and a low friction film disposed on the valve sheathing, with the low friction film in contact with the cylindrical conduit.
16. A method of diverting airflow along an airpath comprising:
- providing a vacuum cleaner comprising a diverter valve assembly comprising a first input port, a second input port, an output port, an automated diverter; and
- moving the automated diverter between the first input port and the second input port so that the output port receives airflow from one of the input ports blocking airflow from the other.
17. The method of claim 16, further comprising determining the position of the automated diverter based on a position of a vacuum handle.
18. The method of claim 16, further comprising:
- receiving airflow from an attachment with the first input port;
- receiving airflow from a beater bar with the second input port; and
- selecting to receive airflow from the first input port when a handle is in a locked position.
19. The method of claim 18, further comprising disabling the first input port when an attachment is not connected to the first input port.
20. The method of claim 18, further comprising raising a portion of a vacuum base to prevent a beater bar from contacting a cleaning surface when the handle is in a locked position.
21. The method of claim 18, further comprising selecting to receive airflow from the second input port when the handle is not in the locked position.
22. The method of claim 16, wherein the vacuum comprises an upright vacuum.
Type: Application
Filed: Apr 30, 2010
Publication Date: Nov 3, 2011
Patent Grant number: 8595893
Inventors: Charles J. Morgan (Sparta, TN), Bruce Kiern (Gulfport, MS)
Application Number: 12/771,884
International Classification: A47L 9/00 (20060101);